A rail robot system and a method thereof

Abstract

The present disclosure provides a rail robot system(100) and a method(300) thereof that improves stability and efficiency for high-speed article(10) transport in material handling systems, used in logistics, manufacturing, warehousing, industrial, commercial, as well as household applications. A support structure 112) holds a rail track network (240) with straight sections (104a), curved sections (104b), and junctions (104c). A rail-guided vehicle (RGV)(102) moves along the network(240), equipped with a chassis (200), a carriage (202) to hold articles (10), a drive unit (232) featuring drive wheels(204), idle wheels (206), and a drive actuator (208), and a diverter unit(230) with diverter wheels (212) and a diverter actuator(214). A diverter rail track section(106) aligns parallel to the curved section (104b), enabling the diverter wheels(212) to engage and stabilize the RGV(102) at high speeds by countering centrifugal forces. This setup ensures smooth navigation through curves and junctions, minimizing wear, maintenance costs, and enhancing safety and productivity.

Description

[0001] A RAIL ROBOT SYSTEM AND A METHOD THEREOF

[0002] FIELD

[0003] The present disclosure relates to robot systems, particularly focusing on the stability and reliability of such robots.

[0004] DEFINITION

[0005] As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicates otherwise.

[0006] Articles: The term "articles" can include packages, carton boxes, intermediary products, raw materials, finished goods with or without primary packaging, finished goods with primary & secondary packaging, finished goods with primary, secondary, and tertiary with or without additional layers of packaging, and other related items.

[0007] The above definitions are in addition to those expressed in the art.

[0008] BACKGROUND

[0009] The background information herein below relates to the present disclosure but is not necessarily prior art.

[0010] Rail robots, also known as rail-guided vehicles (RGVs), are automated systems configured to transport articles along a predefined path on a rail track, as planned by a system controller. These robots are an integral part of modem material handling systems, used in logistics, manufacturing, warehousing, industrial, commercial as well as household application., where they ensure efficient, reliable, and rapid movement of materials between various points within a facility containing one or multiple pick up points as well as one or multiple drop points, managed by the system controller.

[0011] Rail robots operate by following the guided rail track that outlines their route. The rail track can be configured to cover various operational areas, including loading and unloading zones, storage areas, and processing stations. These robots are equipped with wheels that run along rail tracks, and they are typically powered by electric motors. Rail tracks are not always straight; they often include curves and junctions to cover different areas of a facility efficiently. These turns can be challenging for rail robots to navigate, especially at high speeds. The design of the rail track and the robot's ability to handle directional changes are crucial for maintaining operational efficiency and safety.

[0012] In the current state of rail robots, several critical issues compromise their efficiency and safety. One of the primary issues with current high-speed rail robots is their instability during directional changes. Currently, robots slow down before turning. However, when attempts are made to turn at high speeds (above 1 m / s), the following problems arise

[0013] When the speed of these robots is increased, they often become unstable while travelling along a curved track, when changing direction, or while passing through a junction or a curved section. Moreover, they may experience impact forces on the junctions, which aggravate at higher speeds. This instability or impact results in jerky movements, which can disrupt the smooth operation of the robot. Additionally, the instability or impact can lead to mechanical wear and tear of various drive system components of the robot and rail track, resulting in higher maintenance costs and more frequent repairs. The cumulative effect of these disruptions can cause a significant decrease in operational efficiency, affecting the overall productivity of the high-speed rail system.

[0014] As a result of these issues, there is a significant limitation on the speed of current rail robots. Increasing the speed aggravates the instability and performance concerns, making it impractical to operate these robots at higher speeds without compromising safety and reliability. This speed limitation directly impacts the efficiency and competitiveness of the rail robot-based transport system, as the robots are unable to operate at their full potential. The combined effect of instability or impact during directional changes and poor performance on curved tracks poses a significant risk to the safe and secure transport of articles at higher speeds.

[0015] Therefore, there is felt a need for a rail robot system and a method thereof that alleviates the aforementioned drawbacks.

[0016] OBJECTS

[0017] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows: It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.

[0018] An object of the present disclosure is to develop a rail robot system.

[0019] An object of the present disclosure is to provide a system that maintains robot stability when changing direction, even at higher speeds.

[0020] Another object of the present disclosure is to provide a system that reduces jerky movements of a robot at junctions and ensures smooth operation.

[0021] Still another object of the present disclosure is to provide a robot that can navigate through curved tracks without oscillating.

[0022] Yet another object of the present disclosure is to provide a system that prevents the destabilization of the robot and ensures safe transit of articles.

[0023] Yet another object of the present disclosure is to provide a system that can operate at its full potential.

[0024] Another object of the present disclosure is to provide a system that increases the competitiveness of a rail robot system in the material handling industry, including logistics, manufacturing, warehousing, industrial, commercial as well as household applications

[0025] Yet another object of the present disclosure is to provide a system that reduces the maintenance cost and time in the rail robot systems.

[0026] Still another object of the present disclosure is to provide a system that reduces the rate of failure due to wear and tear of rail tracks or robot parts

[0027] Yet another object of the present disclosure is to provide a system that reduces the extent of manual involvement in material handling by augmenting the material handling operations using the rail robot system in an economically viable manner.

[0028] Yet another object of the present disclosure is to provide a method for a rail robot system.

[0029] Other objects and advantages of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying figures, which are not intended to limit the scope of the present disclosure. SUMMARY

[0030] The present disclosure provides a rail robot system for transporting articles, comprising: a support structure, at least one rail-guided vehicle (RGV), and at least one diverter rail track section.

[0031] The structure supporting a rail track network, rail track network comprises straight rail track sections, curved rail track sections, and junctions.

[0032] The rail-guided vehicle (RGV) is configured to travel along the rail track network, the RGV comprising a chassis, a carriage, a drive unit, and a diverter unit.

[0033] The carriage is connected to the chassis and configured to hold and transport articles.

[0034] The drive unit includes drive wheels, idle wheels, and a drive actuator configured to propel the RGV along the rail track network.

[0035] In an alternative embodiment, all wheels may be configured as drive wheels, without the use of idle wheels.

[0036] The diverter unit, including diverter wheels and a diverter actuator configured to engage the diverter wheels to select the path and stabilize the RGV during high-speed travel along the curved rail track sections, junctions, and straight rail track sections.

[0037] The diverter rail track section runs parallel to the curved rail track section, wherein the diverter wheels engage with the diverter rail track section to counter centrifugal forces during highspeed travel.

[0038] In an embodiment, the junctions comprise Y-type junctions and Plus-type junctions to enable the RGV to choose between different paths.

[0039] In an embodiment, the diverter unit is configured to engage the diverter wheels with the diverter rail track section when the RGV operates at a speed exceeding a predetermined threshold, or at any speed, including speeds lower than, at, or higher than the threshold.

[0040] In an embodiment, the diverter rail track section begins before the curved rail track section and extends beyond the curved rail track section, running parallel to the rail track network.

[0041] In an embodiment, the diverter actuator is selected from a group comprising motors, hydraulic systems, gear mechanisms, pneumatic systems, and electro-mechanical actuators. In an embodiment, further comprising a guide wheel actuator configured to rotate front and rear guide wheels of the RGV towards a left or right side to assist in path changes at the junctions.

[0042] In an embodiment, the carriage is connected to the chassis through a pivot configured to permit the carriage to swing laterally, and a damper is configured inside the pivot to dampen angular displacement of the carriage during travel on the straight rail track sections and curved rail track sections.

[0043] In an embodiment, the diverter rail track section is positioned at a lower height beside the carriage to counter centrifugal forces experienced during high-speed travel along the curved rail track sections.

[0044] In an embodiment, the carriage comprises a conveyor base configured to load articles at a loading station and unload articles from said carriage to loading stations(s) positioned beside or below said rail track network; or a split tray or flap mechanism configured to selectively open and release the articles downward into the loading station(s); or a basket configured for manual loading and retrieval of articles.

[0045] In an embodiment, further comprising auxiliary wheels positioned at the front and rear ends of the RGV, as these wheels shall prevent dipping at both plus junctions as well as y junctions

[0046] In an embodiment, the chassis comprises two sections, each section supporting separate drive wheels, and the two sections are interconnected by a tie rod to improve stability.

[0047] In an embodiment, the carriage comprises a displaceable portion configured to extend downwards for loading or unloading or storage or retrieval of articles, the displaceable portion being actuated by a carriage actuator comprising a motorized pulley string, or pulley belt, or scissor mechanism, or sprocket chain, or ball screw mechanism, or rigid chain mechanism arrangement.

[0048] In an embodiment scissor mechanism is added to prevent the lowered carriage from swaying.

[0049] In an embodiment, further comprising a robot control unit configured to control operations of the RGV, including speed regulation, diverter actuator control, and collision avoidance.

[0050] In an embodiment, further comprising a system control unit configured to communicate with the robot control unit and manage overall operations of the rail robot system, including path determination, dynamic path update, congestion avoidance, robot - robot synchronization, human - robot synchronization, human / robot wait time minimization, configuration & system state management, recovery from planned / unplanned slowdown / shutdown and speed optimization.

[0051] In an embodiment, the RGV further comprises a gripper arm or gripper mechanism configured for the storage and retrieval of articles.

[0052] In an embodiment, further comprising sensors configured for relative speed detection and synchronization to avoid collisions between multiple RGVs during high-speed travel.

[0053] In an embodiment, the rail track network includes sensor modules positioned at intervals to monitor the position and speed of the RGV.

[0054] In an embodiment, the rail track network includes sensor modules positioned at intervals to monitor and communicate with the RGV to control the robot position, robot speed, and avoid inter RGV collision.

[0055] In an embodiment, the RGV includes a communication module configured to transmit and receive data to and from a system control unit for coordination and control purposes.

[0056] The present disclosure provides a method for operating a rail robot system, the method comprising:

[0057] • providing a support structure supporting a rail track network, wherein the rail track network comprises straight rail track sections, curved rail track sections, and junctions;

[0058] • providing at least one rail-guided vehicle (RGV) configured to travel along the rail track network, wherein the RGV comprises a chassis, a carriage connected to the chassis and configured to hold and transport articles, a drive unit including drive wheels, and a drive actuator, at least one diverter rail track section running parallel to the curved rail track section, and a diverter unit including diverter wheels and a diverter actuator ;

[0059] • propelling the RGV along the rail track network using the drive actuator;

[0060] • detecting an approaching curved rail track section;

[0061] • engaging the diverter wheels with the diverter rail track section using the diverter actuator with the diverter wheels to divert and stabilize the RGV during high-speed travel along the straight rail track sections, junctions, and curved rail track sections

[0062] • transporting articles using the carriage connected to the chassis of the RGV; and

[0063] • navigating junctions within the rail track network by guiding the RGV along selected paths.

[0064] BRIEF DESCRIPTION OF ACCOMPANYING DRAWING

[0065] The rail robot system and a method thereof, of the present disclosure will now be described with the help of the accompanying drawing, in which:

[0066] Figure 1 illustrates a layout diagram of the existing system, in accordance with prior art.

[0067] Figure 2 illustrates a side view of a rail guided robot in accordance with a first embodiment of the present disclosure;

[0068] Figure 3 illustrates a front view of the system in accordance with a first embodiment of the present disclosure;

[0069] Figure 4A illustrates a top view of the system with Y junction in accordance with the first embodiment of the present disclosure;

[0070] Figure 4B illustrates a top view of the system with Plus (+) junction in accordance with the first embodiment of the present disclosure;

[0071] Figure 5A illustrates a top view of the robot according to a second embodiment of the present disclosure;

[0072] Figure 5B illustrates a side view of the robot according to the second embodiment of the present disclosure;

[0073] Figure 6A illustrates a front view of the robot in accordance with a third embodiment of the present disclosure;

[0074] Figure 6B illustrates a front view of the robot in accordance with the third embodiment of the present disclosure, where robot is in swing position; Figure 7 illustrates a front view of the system in accordance with a fourth embodiment of the present disclosure;

[0075] Figure 8 illustrates a front view of the robot according to a fifth embodiment of the present disclosure, where the carriage is lowered;

[0076] Figure 9 illustrates a top view of the robot in accordance with a sixth embodiment of the present disclosure, where auxiliary wheels are added at both the ends of the robot;

[0077] Figure 10 illustrates a side view of the robot in accordance with a seventh embodiment of the present disclosure, where chassis is divided into two parts;

[0078] Figure 11 illustrates a side view of a rail-guided vehicle (RGV) within a rail robot system, in accordance with an embodiment of the present disclosure.;

[0079] Figures 12A and 12B illustrate a method for a rail robot system, in accordance with an embodiment of the present disclosure.;

[0080] Figure 13 illustrates a layout diagram of the rail robot system, in accordance with the present disclosure;

[0081] Figure 14 illustrates a side view of the rail robot system, in accordance with an eighth embodiment of the present disclosure;

[0082] Figure 15 illustrates a front view of the rail robot system, in accordance with an eighth embodiment of the present disclosure; and

[0083] Figure 16 illustrates a top view of the rail robot system, in accordance with an eighth embodiment of the present disclosure.

[0084] LIST OF REFERENCE NUMERALS USED IN DETAILED DESCRIPTION AND DRAWING

[0085] 1000 Prior Art

[0086] 10 Article

[0087] 100 Rail Robot System 102 Robot / Rail Guided Vehicle (RGV)

[0088] 104 Rail Track Section

[0089] 104a Straight Rail Track Section

[0090] 104b Curve Rail Track Section

[0091] 104c Junctions

[0092] 104cl Y-type Junction

[0093] 104c2 Plus-type intersection

[0094] 106 Diverter Rail Track Section

[0095] 106a Partial Diverter Rail Track Section

[0096] 106b Extended Diverter Rail Track Section

[0097] 106c Second diverter track

[0098] 110 Loading station(s) or Stations ( includes unloading station, storage / retrieval location, receiving bin)

[0099] 112 Support structure

[0100] 200 Chassis

[0101] 200A One Part Chassis

[0102] 200B Another Part of Chassis

[0103] 202 Carriage

[0104] 204 Drive Wheels

[0105] 206 Idle Wheels

[0106] 208 Drive Actuator

[0107] 210 Guide Wheels 212 Diverter Wheel

[0108] 214 Diverter Actuator

[0109] 216 Auxiliary Wheels

[0110] 218 Guide Wheel Actuator

[0111] 220 Pivot

[0112] 222 Carriage Actuator

[0113] 224 String

[0114] 226 Conveyor Base or Split Tray or Basket Base

[0115] 228 Tie Rod

[0116] 230 Diverter Unit

[0117] 232 Drive Unit

[0118] 236 Damper

[0119] 238 Robot Control Unit or System Control Unit

[0120] 240 Rail Track Network

[0121] 240a Sensor Module

[0122] 240b Communication Module

[0123] 242 Gripper Arm

[0124] 300-314 Method and method steps

[0125] DETAILED DESCRIPTION

[0126] Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing. Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details, are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

[0127] The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be is intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, elements, modules, units, and / or components, but do not forbid the presence or addition of one or more other features, elements, components, and / or groups thereof.

[0128] Rail robots (rail-guided vehicles) are automated systems used to transport materials along fixed tracks in material handling systems, used in logistics, manufacturing, warehousing, industrial, commercial as well as household applications. They currently operate safely at low speeds but face instability issues at high speeds (above 1 m / s), especially on curves and junctions. This instability or impact causes jerky motion, accelerates mechanical wear on both the robot and track, and raises maintenance costs. These challenges limit the maximum safe speed of rail robots, reducing their efficiency and productivity. Enhancing their ability to handle directional changes smoothly at higher speeds is essential for improving overall system performance and safety.

[0129] Therefore, the present disclosure envisages a rail robot system and a method thereof (hereinafter referred to as system (100), method (300)). The present disclosure is explained with reference to Figures 1 to 16.

[0130] In accordance with one aspect of the present disclosure, there is provided a rail robot system (100) comprising: a support structure (112), at least one rail-guided vehicle (RGV) (102), and at least one diverter rail track section (106). The support structure (112) which has super and sub structure supporting a rail track network (240), wherein the rail track network (240) comprises straight rail tracks section (104a), curved rail tracks section (104b), and junctions (104c).

[0131] The rail-guided vehicle (RGV) (102) is configured to travel along the rail track network (240). The RGV (102) comprises: a chassis (200), a carriage (202), a drive unit (232), and a diverter unit (230).

[0132] The carriage (202) is connected to the chassis and configured to hold and transport articles (10).

[0133] The drive unit (232), including drive wheels (204), idle wheels (206), and a drive actuator (208) configured to propel the RGV (102) along the rail tracks.

[0134] In an alternative embodiment, all wheels may be configured as drive wheels, without the use of idle wheels.

[0135] The diverter unit (230), including diverter wheels (212) and a diverter actuator (214) configured to engage the diverter wheels (212) with the diverter rail track section ( 106) to select the path and stabilize the RGV (102) during travel along the curved rail track section (104b) as well as on the straight rail track (104a).

[0136] The diverter rail track section (106) runs parallel to the curve rail track section (104b).

[0137] In an embodiment, the junctions comprise Y-type junctions (104cl) and Plus (+) type (104c2) junctions (104c) to enable the RGV (102) to choose between different paths.

[0138] In an embodiment, the diverter unit (230) is configured to enable the diverter wheels (212) to engage with diverter rail track section ( 106) when the RGV ( 102) operates at a speed exceeding a predetermined threshold, or at any speed, including speeds lower than, at, or higher than the threshold.

[0139] In an embodiment, the diverter rail tracks section (106) begins before the curved rail tracks section (104b) and extends beyond them, running parallel to the rail tracks.

[0140] In an embodiment, the diverter actuator (214) is selected from a group comprising motors, hydraulic systems, gear mechanisms, pneumatic systems, and electro-mechanical actuators. In an embodiment, the system (100) further comprises a guide wheel actuator (218) configured to rotate front guide wheels (210) of the RGV (102) towards the left or right side to aid in path changes at junctions (104c).

[0141] In an embodiment, the carriage (202) is configured to connect to the chassis (200) through a pivoted connection permitting the carriage (202) to swing laterally.

[0142] In an embodiment, a damper (236) is configured inside the pivot to dampen angular displacement of the carriage (202) during travel on straight ( 104a) and curved rail track sections (104b).

[0143] In an embodiment, the diverter rail tracks section ( 106) is configured to be positioned at a lower height beside the carriage (202) to counter centrifugal forces experienced during high-speed travel along the curved tracks section (104b).

[0144] In an embodiment, the carriage (202) comprises a conveyor base configured to load articles at a loading station (110) and unload articles from said carriage to stations(s) (110) positioned beside or below said rail track network; or a split tray or flap mechanism configured to selectively open and release the articles downward into the loading stations(s) (110) ; or a basket configured for manual loading at station (110) and manual retrieval of articles at stations (HO).

[0145] In an embodiment, a split tray or flap mechanism is configured to selectively open and push the articles (10) downward into the loading stations(s) (110).

[0146] In an embodiment, the system (100) further comprises auxiliary wheels (216) added at the front and rear ends of the RGV (102) to prevent drive wheels from dipping into cutouts at both Plus (+) ( 104c 1) and Y junctions (104c2).

[0147] In an embodiment, the chassis (200) is constructed into two sections, each section supporting separate drive wheels and idle wheels (206) and interconnected by a tie rod (228) to improve stability.

[0148] In an embodiment, the carriage (202) comprises a displaceable portion configured to extend towards station(s) (110) for unloading or loading or storage or retrieval of articles (10), actuated by a motorized pulley and string or pulley and belt or scissor mechanism or chain or ball screw mechanism, or rigid chain mechanism arrangement. In an embodiment, the system (100) is further comprising a robot control unit (238) configured to control operations of the RGVs (102), including speed regulation, diverter actuator control, and collision avoidance.

[0149] In an embodiment, the robot control unit (238) is configured to communicate with the robot control units (238) and manage overall operations of the rail robot system, including path determination, dynamic path update, congestion avoidance, robot - robot synchronization, human - robot synchronization, human / robot wait time minimization, configuration & system state management, recovery from planned / unplanned slowdown / shutdown and speed optimization.

[0150] In an embodiment, the RGV (102) is equipped with a gripper arm or gripper mechanism for the storage and retrieval of articles (10), enhancing the flexibility and effectiveness of the system.

[0151] In an embodiment, the system (100) is further comprised sensors configured for relative speed detection and synchronization to avoid collisions between multiple RGV sections (102) during high-speed travel.

[0152] In an embodiment, the RGV (102) further comprises a power supply unit configured to provide electrical power to the drive unit (232), diverter unit (230), and other electronic components of the RGV (102).

[0153] In an embodiment, the rail track sections (104) comprise elevated sections and descending / ascending sections, and the RGV (102) is configured to adjust its speed and stability accordingly.

[0154] In an embodiment, the rail track network (240) includes sensor modules (240a) positioned at intervals to monitor and communicate with the RGV (102) to control the robot position, robot speed, and avoid inter RGV(102) collision.

[0155] In another embodiment, the system (100) has markers, and the robots (102) are configured to scan the markers and determine their position in the rail track network (240).

[0156] In another embodiment, the markers are chosen from a range of options, including but not limited to Barcodes, RFID Tags (Radio-Frequency Identification), NFC Tags (Near Field Communication), Datamatrix Codes, Watermarks, Microdots, Holograms, or the like. In an embodiment, the RGV (102) includes an onboard diagnostic system to monitor the operational status and health of the drive unit (232), diverter unit (230), and other critical components.

[0157] In an embodiment, the system (100) further comprises emergency stop mechanisms at designated locations along the rail track network (240) to halt the RGV (102) in the case of an emergency.

[0158] In an embodiment, the system (100) is configured to have a remote -control panel or dashboard configured with an emergency stop to halt the system (100) in the case of any emergency.

[0159] In an embodiment, the RGV (102) includes a communication module (240b) configured to transmit and receive data to and from a system control unit (238) for coordination and control purposes.

[0160] In another embodiment, the communication module (240b) of the RGV (102) is configured to communicate with nearby RGVs (not shown) or sensor modules (240a) of the rail track network (240) for coordination and control.

[0161] In an embodiment, the diverter wheels (212) are configured with an adjustable height mechanism to ensure optimal engagement with the diverter rail track section (106).

[0162] In an embodiment, the RGV (102) includes a cooling system to regulate the temperature of the drive unit (232) and other electronic components during operation.

[0163] In an embodiment, the RGV (102) is equipped with a camera system for visual inspection and monitoring of the rail tracks and the surrounding environment.

[0164] In another embodiment, RGV (102) is equipped with a camera system for collision avoidance and article monitoring.

[0165] In an embodiment, the system (100) further comprises automatic lubrication systems for maintaining the rail tracks (104) and ensuring smooth travel of the RGV (102).

[0166] In an embodiment, the RGV (102) is configured with an adjustable suspension to maintain stability and comfort during high-speed travel over uneven rail tracks. In an embodiment, the rail track network (240) includes safety barriers and warning signals at critical points to prevent unauthorized access and ensure safe operation.

[0167] In an embodiment, the RGV (102) is capable of operating in autonomous mode, with preprogrammed routes and schedules for article (10) operations, such as loading, unloading, storage, retrieval, processing, etc.

[0168] In an embodiment, the carriage (202) is constructed with modular sections that is reconfigured or replaced based on the type and size of articles (10) being transported.

[0169] In an embodiment, the RGV (102) includes lighting systems to illuminate the rail tracks during low visibility conditions.

[0170] In an embodiment, the RGV (102) is equipped with collision avoidance programs that utilize data from sensors to navigate around obstacles and communicate with the robot control unit to avoid collision with other RGV other RGVs (102).

[0171] In an embodiment, the rail track network (240) is developed with sound-absorbing materials to minimize noise generated by the RGV (102) during high / low speed travel.

[0172] In an embodiment, the system (100) includes maintenance bays equipped with diagnostic tools and repair equipment for servicing the RGVs (102).

[0173] In an embodiment, the RGV (102) is configured to tow or push an unhealthy or faulty RGV(102) to a maintenance area.

[0174] In an embodiment, the RGV (102) is configured with a retractable canopy to protect the carriage (202) and articles (10) from external environmental conditions.

[0175] In an embodiment, the system (100) includes an energy-efficient mode of operation, reducing power consumption during off-peak hours or when RGVs (102) are not in use.

[0176] A preferred embodiment of a rail robot system (100), a method (300) thereof of the present disclosure will now be described in detail with reference to Figures 1 to 16. The preferred embodiment does not limit the scope and ambit of the present disclosure.

[0177] Figure 1 illustrates a layout diagram of the existing system, in accordance with prior art. The existing system (1000) comprises an overhead rail track network (240) defined by a plurality of rail tracks (104) and junctions (104c). The rail tracks (104) are supported on a support structure (112). The support structure (112) is made up of a network of beams and columns. The system (100) can include at least one loading station (110) (including loading, unloading, storage, retrieval, processing, etc.) located preferably below a straight rail track (104a). A robot (102) with a carriage (202) is configured to hold and transport articles (10) along the rail track (104). A plurality of loading stations (110) or Activity Zones (Loading, Unloading, Storage, Retrieval) is positioned below or beside the rail track (104) at various locations as shown in Figure 1. The robot (102) is configured to receive articles (10) at the Station(s) (110) and convey them along a predetermined / re-routed path to the corresponding station(s) (110) as per the operational needs.

[0178] The support structure (112) is configured to support the rail track (104), providing the stability and framework for the system (100). The rail track (104) can provide a fixed pathway that outlines the route for the robots (102). The rail track (104) can also include a curved rail track section (104b). The rail track (104) can have junctions (104c) that allow the robots (102) to change path. The rail track (104) can have different types of junctions (104c), such as Y-Type Junctions ( 104c 1) and Plus (+) (104c2) Type Junctions. Y-Type Junctions ( 104c 1) can enable the robot (102) to choose between two diverging paths, providing flexibility in route selection. This configuration can allow the robot (102) to navigate to different destinations based on operational needs.

[0179] The robot (102), while travelling along the curved track segments (104b) experiences centrifugal force. As the magnitude of centrifugal force is proportional to the square of the speed along the curved track (104b), even a small increment in the robot (102) speed causes a major rise in centrifugal force. Therefore, while navigating along the curved track (104b) segment at higher / lower speeds, a large amount of lateral unbalanced centrifugal force induces vibrations, instability in the robot's (102) movement, and the rail track (104). Moreover, while changing lanes, some of the robot wheels transition from one rail segment to another. This transition leads to impact forces which aggravate at higher speeds.

[0180] To tackle this issue, the rail robot system (100) according to the present disclosure provides diverter rail tracks (106) running parallel to the curved track (104b) segment and diverter wheels (212) connected on the lateral side of the robot ( 102) and configured to be guided inside the diverter rail tracks section (106) while navigating along the straight (104a) and curved track section (104b) segments. In an embodiment, the diverter track (106) begins before the start of the curved track segment and also extends beyond the curved track segment (104b) by running parallel to the rail track section (104). The diverter rail tracks (106) are strategically positioned based on the design of the overall support structure (112) supporting the rail track (104).

[0181] In an embodiment, the diverter rail track (106) is positioned beside the rail track (104). In another embodiment, the diverter rail track (106) is positioned at a lower height beside the carriage (202).

[0182] Figures 2-4 illustrate the first embodiment of the rail robot system (100), according to the present disclosure. Figure 2 illustrates a side view of the robot (102) in accordance with the first embodiment of the present disclosure. The high-speed rail robot system (100) can have a plurality of robots (102) configured to travel along the rail track (104) and handle the loading / unloading / Storage / Retrieval / processing of articles (10) at designated stations (110). Each robot (102) includes a drive unit (232) configured to propel the robot (102) along the rail track ( 104) . The robot ( 102) includes the chassis (200) configured to support different elements of the drive unit. The carriage (202) is connected to the operative bottom side of the chassis (200).

[0183] The drive unit can include drive wheels (204) driven by a drive actuator (208). The drive unit can also include idle wheels (206) configured to support and guide the robot (102) along the rail track (104). The drive wheels (204), driven by the drive actuator (208) is propel the robot (102) along the rail track (104), providing the necessary movement and speed. The drive unit (232) further includes a set of guide wheels (210) on the operative front and rear sides of the chassis (200). The guide wheels (210) are configured to run within the rail track (104) and are aligned horizontally to provide support against lateral forces in the rail track (104).

[0184] In an embodiment, at least one set of the diverter wheels (212) is configured on the robot ( 102) . The diverter wheels (212) are configured for navigating the robot (102) to the diverter rail tracks (106). The diverter actuator (214) can actuate the diverter wheels (212) to either side of the robot (102), i.e., to the left or right. If the robot (102) wants to take a left turn, the diverter wheels (212) are engaged in the diverter rail track (106) on the left, and the diverter rail track (106) can guide the robot (102) in that direction. Similarly, if the robot (102) wants to take a right turn, the diverter wheels (212) are engaged in the diverter rail track (106) on the right, guiding the robot (102) accordingly. The diverter wheels (212) are actuated by the diverter actuator (214). In another embodiment, an extra set of diverter wheels (212) is mounted on the front and rear sides of the robot (102).

[0185] In an embodiment, a second diverter rail track (106c) is configured to be mounted parallel to the rail track (104) on the opposite side of the diverter rail track (106) at the junctions. As shown in Figure 4A, when the robot (102) wants to turn right, the diverter wheels (212) are engaged in an extended diverter rail track (106b), and the robot (102) can travel along the straight rail track section ( 104a) . Similarly, when robot ( 102) wants to travel straight, then robot (102) can engage the diverter wheels (212) in the second diverter rail track (106c) on the opposite side of the extended diverter rail track (106b) and travel along the rail track section (104), without turning. In another embodiment, the diverter actuator (214) is chosen from a range of options, including but not limited to motors, hydraulic systems, gear mechanisms, pneumatic systems, electro-mechanical actuators, or the like.

[0186] Figure 5A and 5B illustrate a top and a side view of the robot (102) according to the second embodiment of the present disclosure, where a guide wheel actuator (218) is configured to rotate the front guide wheels (210) toward the operative left and right sides of the robot (102). The rotation of front guide wheels (210) can aid the robot (102) in easily changing the paths at junctions. It can also help to reduce the impact and noise of the robot (102) when entering a curved rail track (104b).

[0187] In another embodiment, the guide wheel actuator (218) is chosen from a range of options, including but not limited to motors, hydraulic systems, gear mechanisms, pneumatic systems, electro-mechanical actuators, or the like.

[0188] Figures 6A and 6B illustrate a front view of the robot (102) in accordance with the third embodiment of the present disclosure, where the carriage (202) is connected to the chassis (200) through a pivoted (220) connection. The pivot (220) is configured to permit the carriage (202) to swing along the lateral direction. This can shift the effective centre of centrifugal force upwards towards the rail track (104). To counter these centrifugal forces, the diverter track (106) can also be shifted upward, closer to the rail track (104). The pivot (220) can help to balance the centrifugal forces experienced by the robot (102) at the time of turning on the curved rail tracks (104b).

[0189] According to the fourth embodiment of the present disclosure, a partial rail diverter track (106a) is configured to accommodate the wide swing of the carriage (202) at relatively higher speeds. When the robot (102) needs to turn right, the partial diverter track (106a) is set up only on the left side of the rail track (104), while the left side of the rail track remains open to facilitate the wide swing of the robot (102). Figure 7 illustrates the wide swing of the carriage (202) along the curved rail track (104b) on the partial rail diverter track (106a).

[0190] Further, a damper is added to the robot (102) according to the third and fourth embodiments of the present disclosure. The damper (236) is configured inside the pivot (220) to dampen the angular displacement that can occur during regular or full swing of the robot (102) while travelling on the curved rail track section (104b). The damper can further enhance the stability of the robots (102) during high-speed travel and directional changes. By moving or shifting up the centre of mass, the system (100) can achieve greater balance and reduce the risk of tilting or oscillation.

[0191] Figure 8 illustrates a front view of the robot (102) according to the fifth embodiment of the present disclosure, where a carriage displacement actuator is used to displace the carriage (202) away from and toward the rail track (104). In an embodiment, the carriage actuator (222) is a motorized pulley, a string (224), a belt, a scissor, a chain, a ball screw mechanism, or rigid chain mechanism arrangement. The string (224) is configured to allow the carriage (202) to displace towards the station (110) (such as Loading / Unloading / Storage / Retrieval / Processing). In another embodiment, other linear actuators can also be used. The carriage (202) displacement in the robot (102) is used to increase the reach of the carriage (202). The displaceable carriage (202) extends the operational range of the robot (102). The displaceable carriage (202) can reduce the distance between the carriage (202) and the loading station (110) to facilitate the handling of articles (10).

[0192] In another embodiment, multiple loading section(s) (110) is stacked vertically to enhance the material handling capacity of the system (100). The displaceable carriage (202) is moved to the desired level of the receiving bin (110) to release the article at the appropriate level within the stack of loading section(s) (110). In another embodiment, a conveyor base (226) is configured inside the carriage (202) at the operative bottom end of the carriage (202). The conveyor base (226) is configured to load and unload the articles (10) from the carriage (202). The conveyor base (226) can displace the articles (10) to either side of the carriage (202) and drop or unload them in the desired receiving bin (110) on either side of the robot (102). In another embodiment, a split tray base (226) is configured inside the carriage (202) at the operative bottom end of the carriage (202). The split-tray base (226) is configured to unload the articles (10) from the carriage (202).

[0193] In another embodiment, a non-motorized Basket base (226) is configured inside the carriage (202) at the operative bottom end of the carriage (202). The basket base (226) is configured to manually load and unload the articles (10) from the carriage (202).

[0194] Figure 9 illustrates a top view of the robot (102) in accordance with the sixth embodiment of the present disclosure, where auxiliary wheels (216) are added at the front and rear ends of the robot (102). The auxiliary wheels (216) are configured to prevent the drive wheels (204) from dipping into the cutouts in both plus (+) ( 104c2) and Y j oints ( 104c 1 ) j unctions on the rail track (104). When the robot (102) wants to cross the junction (104c) or a plus intersection (104c2), the auxiliary wheels (216) are configured to support the robot ( 102) and avoid dipping the robot (102) into the groove of the rail track (104). When the drive wheels (204) and guide wheels (210) passes through the junction (104c) or a plus intersection (104c2), they looses the contact with the rail track (104), in this scenario the auxiliary wheels (216) can provide the support to the robot (102) to maintain the stability at junction (104c) or a plus intersection (104c2).

[0195] Figure 10 illustrates a side view of the robot (102) in accordance with a seventh embodiment of the present disclosure, where the chassis (200) is divided into two parts. One part of the chassis (200A) is configured to support the drive wheels (204), and another part of chassis (200B) is configured to support either the drive wheels (204) or idle wheels (206). Both parts of the chassis (200) are connected to each other by the support of a tie rod (228). The tie rod (228) is configured to keep both chassis (200) in two fixed axes of rotation.

[0196] In one embodiment, both chassis collectively contain four pairs of wheels, including drive wheels and idle wheels.

[0197] In an alternative embodiment, at least one of the four sets of wheels is a drive wheel (powered), and the remaining are idle (non-powered).

[0198] In an embodiment, all four pairs of wheels are powered.

[0199] In another embodiment, each part of the chassis (200) can have a separate set of guide wheels (210) and diverter wheels (212). In another embodiment, a gripper arm (242) or gripper mechanism is installed on the carriage (202). The gripper arm is utilized for the storage and retrieval of articles (10). By using a gripper arm (242), the robot (102) can efficiently handle items by gripping, lifting, and placing them with precision. By incorporating a gripper arm (242), the robot (102) can enhance its capability to manage various types of cargo, improving the flexibility and effectiveness of storage and retrieval operations.

[0200] In another embodiment, a latching mechanism (242) is installed on the carriage (202). The latching mechanism is utilized for the storage and retrieval of totes containing articles (10).

[0201] Figure 11 illustrates a front view of a rail-guided vehicle (RGV) (102) within a rail robot system, as per the provided disclosure. The RGV (102) operates along a rail track section (104), supported by a support structure (112) depicted as vertical beams. The chassis (200) forms the upper part of the RGV (102), interfacing with the rail track (104) through wheels, likely including drive wheels and idle wheels (not shown). A carriage (202) suspends below the chassis (200), configured to hold and transport articles. The carriage (202) appears as a black rectangular container with rounded edges. Diverter wheels (212) are mounted on the carriage (202) engaged on the right side of the RGV (102), for right side turning, positioned to engage with a diverter rail track section (106), which runs parallel to the main rail track (104). This setup stabilizes the RGV (102) during high-speed travel, particularly on curved sections, by countering centrifugal forces.

[0202] Figures 12A and 12B illustrate a flow chart depicting the steps involved in a method for a rail robot, in accordance with an embodiment of the present disclosure. The order in which method (300) is described is not intended to be construed as a limitation, and any number of the described method (300) steps is combined in any order to implement method (300) , or an alternative method (300). Furthermore, method (300) is implemented by processing resource or electronic device(s) through any suitable hardware, non-transitory machine-readable medium / instructions, or a combination thereof. The method (300) comprises the following steps:

[0203] At step (302), the method (300) includes providing a support structure (112) supporting a rail track network (240), wherein the rail track network (240) comprises straight rail track sections (104a), curved rail track sections (104b), and junctions (104c). At step (304), the method (300) includes providing at least one rail-guided vehicle (RGV) (102) configured to travel along the rail track network (240), wherein the RGV (102) comprises the chassis (200), a carriage (202) connected to the chassis (200) and configured to hold and transport articles (10), a drive unit (232) including drive wheels (204), and a drive actuator (208), a diverter rail track section (106) running parallel to the curved rail track section (104b), and a diverter unit (230) including diverter wheels (212) and a diverter actuator (214).

[0204] At step (306), the method (300) includes propelling the RGV (102) along the rail tracks using the drive actuator (208).

[0205] At step (308), the method (300) includes detecting an approaching curved rail track section (104b).

[0206] At step (310), the method (300) includes engaging the diverter wheels (212) with the diverter rail track section (106) running parallel to the curved rail track section (104b) using the diverter actuator (214) to stabilize the RGV (102) during high-speed travel along the straight (104a) and curved rail track section (104b).

[0207] At step (312), the method (300) includes transporting articles (10) using the carriage (202) connected to the chassis (200) of the RGV (102).

[0208] At step (314), the method (300) includes navigating junctions (104c) within the rail track network (240) by guiding the RGV (102) along the selected paths.

[0209] Figure 13 illustrates a layout diagram of the rail robot system, in accordance with the present disclosure. Figure 13 describes the layout and is provided for understanding purposes, where this disclosure shows the diverting part, which has arcs alongside the curved rail track sections (104b). Although the arcs are shown only along curved sections (104b), it is envisaged that at least on one end of the diverter track rail section (106) can extend towards part of the straight section (104a) as seen particularly in figure 4a and figure 4b marked as section (106b).

[0210] Figure 14 illustrates the side view and figure 15 illustrates a front view of the rail robot system, in accordance with an eighth embodiment of the present disclosure, where the rail tracks (104) is mounted on the top side of the support structure (112) and the robot (102) can travel on top side of the rail track (104). The carriage (202) is mounted on the top side of the chassis (200). In this embodiment, the loading stations(s) (110) are placed on either side of the rail track to load or unload them at the desired station (110) on either side of the robot (102).

[0211] Figure 16 illustrates a top view of the rail robot system, in accordance with an eighth embodiment of the present disclosure. The robot (102) is configured to travel on the top side of the rail track (104). The drive unit (232) and the diverter unit (230) are positioned on the top side of the rail track (104) and beneath the chassis (200) of the robot (102). The articles (10) are placed on a platform mounted on the top side of the chassis (200) of the robot (102).

[0212] In an embodiment, the carriage (202) of the rail robot system (100) comprises a diverter unit (230) equipped with two sets of diverter wheels (212), one set positioned at the top and another at the bottom of the carriage (202), both located close to the carriage’s central axis. The wheels in each set are angularly spaced apart relative to the central axis to ensure stable engagement with the diverter rail track section (106). This configuration enhances the stability and precision of the rail-guided vehicle (RGV) (102) during diversion manoeuvres, particularly when navigating turns or transitions in the rail track network (240) at varying speeds and varying weight of the carriage.

[0213] In another embodiment, the diverter unit (230) is modified to eliminate at least one diverter wheel (212) from the set, retaining at least one operational diverter wheel. This single-wheel configuration reduces mechanical complexity and weight while maintaining sufficient engagement with the diverter rail track section (106). The remaining diverter wheel is designed to provide adequate guidance for the RGV (102) during diversion, ensuring compatibility with the rail track network (240) while potentially lowering maintenance and manufacturing costs.

[0214] In a further embodiment, the rail robot system (100) includes two chassis, denoted as chassis (200A) and chassis (200B), within the carriage (202). Either chassis (200A), chassis (200B), or both is powered to drive the RGV (102) along the rail track network (240). When both chassis are powered, they operate in tandem to provide enhanced traction and load-bearing capacity, particularly for heavy articles (10). Alternatively, powering only one chassis reduces energy consumption for lighter loads or simpler operations, offering flexibility in system performance based on operational requirements.

[0215] In yet another embodiment, the diverter unit (230) is configured with either a single diverter motor or two diverter motors to actuate the diverter wheels (212). In the single-motor configuration, one motor drives the diverter wheels (212) to engage with the diverter rail track section (106), optimizing simplicity and reducing power requirements. In the dual -motor configuration, two motors provide independent control over separate diverter wheels or sets, enabling finer control and redundancy for high-speed or complex diversion tasks, improving reliability and precision in the rail track network (240).

[0216] In an additional embodiment, the rail track network (240) includes track sections with a slight incline to connect multiple levels of a facility, such as a ground-floor track interconnected with a first-floor track and beyond. The superstructure of the rail robot system (100) comprises at least two distinct levels, each hosting a separate track network. These track networks are interconnected by inclined track sections, allowing the RGV (102) to transition smoothly between different levels (e.g., ground floor to first floor). Each inclined section is designed to connect two track sections at different heights, ensuring seamless movement of the carriage (202) across the multi-level rail track network (240) while accommodating the loading and unloading of articles (10) at various stations.

[0217] In another embodiment, the system (100) is integrated with a robot control unit (238) and a system control unit (238). The robot control unit (238) is configured to control the operations of the robot (102). The robot control unit (238) is equipped with a controller to control the drive actuator (208). The speed of the robot (102) is controlled by the robot control unit (238). The robot control unit (238) is further configured to control the actuation of the diverter actuator (214). The robots are equipped with various sensors, including but not limited to location sensors, proximity / collision avoidance sensors, and robot speed sensors. The robot control unit (238) is configured to communicate with the robot control units (238) of each of the robots. The robot control unit (238) can also communicate with various sensors of individual robots, sensors located on tracks, and input or scanning devices located at the loading station(s) (110) to identify the location of each robot and control the multiple operations of the rail robot system (100). The input or scanning devices on the loading station(s) (110) are configured to scan the article (10) to ensure the correctness of the article(s)(10) and or station(s).

[0218] The system control unit (238) is configured to determine a specific path for each robot, instruct the robot to travel along a pre-determined path as per the operational need, and avoid collision / congest! on between multiple robots while traveling along the rail track. The system controller can appropriately instruct individual robots to increase their speed and reduce their speed to enable high-speed operation at optimum efficiency without any problem. In another embodiment, at least one sensor is either on the track or the robot or both is provided for relative speed detection and synchronization. The sensors can detect the movement of robots (102) and can avoid the collision of two robots (102). This configuration can allow the robot (102) to accurately monitor and adjust its speed in relation to other moving robots (102). By incorporating the sensor, the system (100) can achieve precise synchronization and coordination during high-speed travel.

[0219] In another embodiment, a system controller is configured to coordinate the synchronization of the robots (102) movement. The system controller can communicate with each robot's (102) drive unit (232). The system controller is configured to adjust the speed of travel for each individual robot (102). The system controller is configured to manage the timing and sequence of the robots' (102) movements and prevent collisions or delays.

[0220] Advantageously, the system (100) enables smooth and stable transport of articles (10) at both high and low speeds, including along curves and junctions, while minimizing vibration and ensuring load safety. It allows flexible loading and unloading options to suit different applications and provides reliable navigation with improved stability. Intelligent control and sensing ensure efficient coordination, collision avoidance, and path optimization, while the modular track configuration supports scalability. Overall, the system (100) offers safe, efficient, and continuous operation with high flexibility, reliability, and throughput.

[0221] The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.

[0222] TECHNICAL ADVANCES AND ECONOMICAL SIGNIFICANCE

[0223] The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a rail robot system and a method thereof, that:

[0224] • maintains stability when turning, even at increased speeds;

[0225] • navigates through curved tracks without oscillating; • prevents destabilization of the robot and ensures the safe transit of articles during travel;

[0226] • minimizes the risk of articles being mishandled during travel;

[0227] • operates at higher speeds without compromising stability and safety;

[0228] • enhances the overall productivity and efficiency of the high-speed rail system;

[0229] • decreases mechanical wear and tear on high-speed rail robots and rail tracks;

[0230] • reduces the frequency of repairs and associated maintenance costs;

[0231] • transports articles securely and reliably;

[0232] • reduces the likelihood of accidents and mishaps, improving the safety of the rail system;

[0233] • increases the robots' speed to exceed 2.5 m / s ;

[0234] • operates at the maximum permissible operating speed of the robots;

[0235] • path planning and dynamic re-routing to avoid congestion;

[0236] • managing loading of article(s) from one or multiple loading points and unloading of article(s) from one or multiple unloading points.

[0237] • synchronizing movements of robots and humans as per a predefined optimization strategy;

[0238] • storing configuration and system state details for faster initialization / startup / recovery;

[0239] • increases the competitiveness of high-speed rail systems in the material handling systems, used in logistics, manufacturing, warehousing, industrial, commercial, as well as household applications; and

[0240] • reduces the extent of manual involvement required in material handling by augmenting the material handling operations using the rail robot system in an economically viable manner. The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and / or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

[0241] Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, or group of elements, but not the exclusion of any other element, or group of elements.

[0242] While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

Claims

CLAIMS:

1. A rail robot system (100) for transporting articles (10), said system (100) comprising:• a support structure (112) supporting a rail track network (240), said rail track network (240) comprises at least one straight rail track section (104a), at least one curved rail track section (104b), and at least one junctions (104c);• at least one rail-guided vehicle (RGV) (102) configured to travel along the rail track network (240), said RGV (102) comprising: o a chassis (200); o a carriage (202) connected to said chassis (200) and configured to hold and transport articles (10); o at least one drive unit (232) including drive wheels (204), and a drive actuator (208) configured to propel said RGV (102) along the rail track network (240); and o at least one diverter unit (230) including diverter wheels (212) and a diverter actuator (214) configured to engage said diverter wheels (212) with a diverter rail track section (106) to divert and stabilize the RGV (102) during high-speed as well as low speed travel along said curved rail track sections (104b), said junctions (104c) and said straight rail track sections (104a); and• said diverter rail track section ( 106) running parallel to the curved rail track section ( 104b), wherein said diverter wheels (212) engage with said diverter rail track section (106) to divert and stabilize the RGV (102) during high-speed as well as low speed travel along said curved rail track sections (104b), said junctions (104c) and said straight rail track sections (104a).

2. The rail robot system (100) of claim 1, wherein said junctions (104c) comprise Y-type junctions (104cl) and / or Plus-type junctions (104c2) to enable the RGV (102) to choose between different paths.

3. The rail robot system ( 100) of claim 1 , wherein said diverter unit (230) is configured to engage the diverter wheels (212) with the diverter rail track section (106) when the RGV (102) travels at any speed, including speeds lower than, at, or higher than the threshold.

4. The rail robot system (100) of claim 1, wherein said diverter rail track section (106) begins before said curved rail track section (104b) and extends beyond said curved rail track section (104b), running parallel to said rail track network (240).

5. The rail robot system (100) of claim 1, wherein said diverter actuator (214) is selected from a group comprising motors, hydraulic systems, gear mechanisms, pneumatic systems, and electro-mechanical actuators.

6. The rail robot system (100) of claim 1, further comprising a guide wheel actuator (218) configured to rotate the front set of guide wheels (210) relative to the rear set of guide wheels and main wheels of the RGV ( 102) towards a left or right side to assist in path changes at said junctions (104c).

7. The rail robot system (100) of claim 1, wherein said carriage (202) is connected to said chassis (200) through a pivot (220) configured to permit said carriage (202) to swing laterally, and a damper (236) is configured to dampen angular displacement of said carriage (202) during travel on said straight rail track sections (104a) and said curved rail track sections (104b).

8. The rail robot system (100) of claim 1, wherein said diverter rail track section (106) is positioned at a lower height beside said carriage (202) to divert and stabilize the RGV (102) during high-speed and low speed travel along said curved rail track sections (104b), said junctions (104c) and said straight rail track sections (104a).

9. The rail robot system (100) of claim 1, wherein said carriage (202) comprises, a conveyor base configured to load articles at station(s) (110) and unload articles(lO) from said carriage (202 ) to stations(s) (110) positioned beside or below said rail track network (240); or a split tray or flap mechanism configured to selectively open and release the articles (10) downward into station(s) (110); or a basket configured for manual loading of articles at stations (110) and manual retrieval of articles(lO) at stations (110).

10. The rail robot system (100) of claim 2, further comprising auxiliary wheels (216) positioned at the front and rear ends of said RGV (102) to prevent dipping at both plus-type junctions (104c2) as well as y-type ( 104c 1) junctions.

11. The rail robot system (100) of claim 1, wherein said chassis (200) comprises two sections (200A, 200B), each section supporting separate wheels (204 or 206) at least one wheel being driven wheel (204) and other being either driven wheel (204) or idle wheel (206), and said two sections (200A, 200B) are interconnected by a tie rod (228) to improve stability.

12. The rail robot system (100) of claim 1, wherein said carriage (202) comprises a displaceable portion configured to extend downwards for loading or unloading or storage or retrieval or processing of articles(lO), the displaceable portion being actuated by a carriage actuator (222) comprising a motorized pulley string (224), or pulley belt, or scissor mechanism, or sprocket chain, or ball screw mechanism, or rigid chain mechanism arrangement.

13. The rail robot system (100) of claim 1, further comprising a robot control unit (238) configured to control operations of said RGV (102), including speed regulation, diverter actuator (214) control, and collision avoidance.

14. The rail robot system (100) of claim 1, further comprising a system control unit (238) configured to communicate with robot control unit (238) and manage overall operations of the rail robot system (100), including path determination, dynamic path update, congestion avoidance, collision avoidance, inter-robot synchronization, human and robot synchronization, human / robot wait time minimization, configuration & system state management, recovery from planned / unplanned slowdown / shutdown and speed optimization.

15. The rail robot system (100) of claim 1, wherein said RGV (102) further comprises a gripper arm (242) or gripper mechanism configured for storage and retrieval of articles (10).

16. The rail robot system (100) of claim 1, further comprising sensors configured for relative speed detection and synchronization to avoid collisions between multiple RGVs (102) during high or low speed travel.

17. The rail robot system (100) of claim 1, wherein said rail track network (240) includes sensor modules (240a) positioned at intervals to monitor the position and speed of the RGV (102) and communicates with said robot control unit (238) to avoid collision with other RGVs(102).

18. The rail robot system (100) of claim 1, wherein said rail track network (240) includes sensor modules(240a) positioned at intervals to monitor the position and speed of the RGV (102) and communicates with the RGV to control the robot position, robot speed, and avoid inter-RGV collision.

19. The rail robot system (100) of claim 1, wherein said RGV (102) includes a communication module (240b) configured to transmit and receive data to and from a system control unit (238) for coordination and control purposes.

20. A method (300) for operating a rail robot system (100), said method (300) comprising the steps of:• providing (302) a support structure (112) supporting a rail track network (240), wherein the rail track network (240) comprises straight rail track sections (104a), curved rail track sections (104b), and junctions (104c);• providing (304) at least one rail-guided vehicle (RGV) (102) configured to travel along the rail track network (240), wherein said RGV (102) comprises a chassis (200), a carriage (202) connected to the chassis (200) and configured to hold and transport articles (10), a drive unit (232) including drive wheels (204), and a drive actuator (208),a diverter rail track section (106) running parallel to the curved rail track section ( 104b), and a diverter unit (230) including diverter wheels (212) and a diverter actuator (214);• propelling (306) said RGV (102) along said rail track network (240) using said drive actuator (208);• detecting (308) an approaching curved rail track section (104b);• engaging (310) said diverter wheels (212) with said diverter rail track section (106) using said diverter actuator (214) to divert and stabilize the RGV (102) during highspeed as well as low-speed travel along said straight rail track sections (104a), said junctions (104c) and said curved rail track sections (104b);• transporting (312) articles (10) using said carriage (202) connected to the chassis (200) of said RGV (102); and• navigating (314) junctions (104c) within said rail track network (240) by guiding said RGV (102) along selected paths.

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